Removing Fuel Level Sensor - Carrera 2

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2013 Porsche 911, 2012 Porsche 911, 2011 Porsche 911, 2010 Porsche 911, and 2009 Porsche 911. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: Risk of fire from escaping fuel.

Danger of fatal injury and damage to property.

→ Observe basic safety instructions when working on the fuel system, → 2001AW BASIC SAFETY INSTRUCTIONS WHEN WORKING ON THE FUEL SYSTEM .

→ Secure working area.

Tools:

Tool for RoW variant.

Fig 1: Identifying Special Tool (Socket Wrench 3217) (RoW)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Tool for all USA variants of Carrera 4 and Carrera 2.

Fig 2: Identifying Special Tool (Lug Wrench P 9731) (USA)

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

Watch out for emerging fuel when disconnecting fuel lines. Place a clean cloth on the connection point, then loosen the connection.

Information

Watch out for emerging fuel when disconnecting fuel lines. Place a clean cloth on the connection point, then loosen the connection.

Disconnect plug connections on the fuel level sensor.
1. 1.1. Carrera 2/USA variant:
  
  Fig 3: Identifying Plug Connections On Fuel Level Sensor (USA)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. 1.1.1. Release and pull off plug-in couplings on the fuel lines.
  2. 1.1.2. Release and pull off multiple connector.
2. 1.2. Carrera 2/RoW variant:
  
  Fig 4: Identifying Flange Of Fuel Level Sensor (RoW)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. 1.2.1. Release and pull off plug-in couplings on the fuel lines.
  2. 1.2.2. Release and pull off multiple connector.
Unscrew cap on fuel level sensor.
Information

Mark the installation position with a touch-up stick before removing the fuel level sender.

Use special tool for this, depending on the version (USA - RoW).
1. 2.1. Fig 5: Carrera 2/USA variant: Lug wrench P 9731
  Original position of cap.
  
  Fig 5: Removing Fuel Level Sensor (USA)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 2.2. Fig 6: Carrera 2/RoW variant: Union nut tool 3217
  Mark original position of cap.
  
  Fig 6: Removing Fuel Level Sensor (RoW)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Remove fuel level sensor.
1. 3.1. Carefully pull fuel level sensor out of the fuel tank.
2. 3.2. Disconnect plug-in couplings for the fuel line.
  Press locking lugs and pull off the plug-in coupling -1- .
  
  Fig 7: Identifying Fuel Lines On Fuel Level Sensor (Underside)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 3.3. Disconnect electric plug connection.
  
  Fig 8: Disconnecting Electric Plug Connection
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. 3.3.1. Release and pull off two-piece multiple connector from the fuel level sensor -1- .
  2. 3.3.2. Separate the two housing halves (yellow/blue) -2, 3- of the multiple connector.
4. 3.4. Carefully remove the fuel level sensor.
5. 3.5. Replace seal.
Information
- When the work is complete, check that all aids and foreign objects (e.g. cloths, tools) are removed from the engine compartment.
Make sure there are no tools, foreign objects or aids left in the work area.